Autonomous Dock Loading With Guided AMT Trailer Transfer

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Solution Overview

Problem

Current robotic material handling systems for loading and unloading trailers at distribution centers are complex, costly, and prone to errors, requiring extensive sensors and algorithms, which can lead to inefficient and unsafe operations, and often necessitate human intervention due to issues like trailer creep and weight-bearing limitations.

Innovation Solution

An autonomous dock station system utilizing an automated material lift truck (AMT) with a pallet conveyor, guided by facility and trailer guidance systems, that can autonomously load or unload trailers by following a workflow procedure, reducing the need for human intervention and minimizing the risk of trailer movement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If forklift trucks are used to load and unload trailers, then material handling can be performed, but trailer creep occurs causing safety hazards and operational delays

Engineering Contradiction:

Improvematerial handling capabilityVSAvoidtrailer stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces the mechanical forklift system with an automated robotic system that uses sensors, controllers, and automated guidance to perform material handling. This substitution eliminates the manual operation issues that cause trailer creep while maintaining efficient loading and unloading capabilities through automated precision control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The robotic system performs material handling autonomously without human intervention during the loading/unloading process. The system self-navigates, self-positions, and self-operates to move materials, eliminating the need for human operators who inadvertently cause trailer movement through manual forklift operations.

Inventive Principle:

Principle #25Self-service

2Extent of automation

If complex robotic systems with numerous sensors and algorithms are deployed, then automation level increases, but system complexity and cost increase significantly

Engineering Contradiction:

Improveautomation levelVSAvoidsystem complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The patent divides the automated material handling system into modular functional components: navigation module, positioning module, material handling module, and control module. Each module performs a specific function and can be independently optimized, reducing overall system complexity while maintaining high automation levels.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The robotic system is designed with multi-functional capabilities that allow a single integrated platform to perform navigation, positioning, material handling, and communication functions. This universal design reduces the need for multiple separate systems and complex interconnections, thereby reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If existing robotic systems enter the cargo space to stack or unload cargo, then loading efficiency improves, but human access to cargo is blocked requiring system removal and causing delays

Engineering Contradiction:

Improveloading efficiencyVSAvoidcargo access time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The robotic system operates continuously within the cargo space throughout the loading and unloading process without interruption. The system maintains its position and operations continuously, allowing human operators to access cargo simultaneously without requiring the robotic system to exit, thereby eliminating delays and maintaining continuous productivity.

Inventive Principle:

Principle #20Continuity of useful action

4Productivity

If conventional systems service trailers at a rate of 20 per day, then operational capacity is maintained, but cycle time averages 72 minutes per trailer which limits throughput

Engineering Contradiction:

Improvetrailer service capacityVSAvoidcycle time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The automated robotic system enables continuous operation without the interruptions inherent in manual forklift operations. The system can load and unload trailers back-to-back without requiring operator transitions, safety checks, or system repositioning, thereby reducing cycle time and increasing the number of trailers serviced per day beyond the conventional 20-trailer capacity.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS11142413B2Systems and methods for automated loading and unloading at a dock station

Publication Date: 2021.10.12 ASSA ABLOY ENTRANCE SYST AB

AI summary

An autonomous dock station system having an automated material lift truck (AMT), a pallet conveyor, and a facility guidance system can automatically load and/or unload a trailer at a dock station. The autonomous dock station system can coordinate these components according to a workflow procedure. In some embodiments, the workflow procedure can begin with the pallet conveyor supplying a loaded pallet to a specified position. The AMT, initially guided by fixed guidance elements of the facility guidance system, can lift the pallet off the conveyor and transport it to a trailer entrance where the AMT switches from the facility guidance system to a trailer guidance system. The AMT can then carry the pallet to an unloading position, move the pallet to one side of the trailer as needed, unload the pallet and return to the pallet conveyor. The workflow procedure can repeat until the trailer is full.